Method of Manufacturing Packaging Comprising Pharmaceutical Products

ABSTRACT

The method for producing a multi-day package containing various drugs has the following steps: a bottom layer is formed with a plurality of wells arranged in a pattern; a predetermined number of different drugs is arranged in predetermined positions at various dispensing stations of a filling device; the desired number of drugs are picked in a controlled manner from their predetermined positions at each dispensing station by at least one movable suction or gripper device, and the drugs are deposited in the predetermined wells; and a sealing film is applied to the bottom layer to seal off the wells. In the course of this method, in at least one dispensing station several suction or gripper devices, which are arranged in correspondence with the pattern of the wells in the multi-day package and which travel parallel to each other, are actuated individually.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority based on European patent application EP07 008 966.9, filed May 3, 2007.

FIELD OF THE INVENTION

The invention pertains to methods for producing multi-day packages whichcontain various drugs for several days and for several administrationtimes.

DESCRIPTION OF THE PRIOR ART

The multiple blister pockets of conventional blister packs are intendedto hold a single type of medicament. A device for filling theseconventional blister packs is described in, for example, DE 199 26 893C2.

In the treatment of patients with chronic diseases, however, there isoften room for improvement with respect to the patient's ability to takehis or her medicaments consistently in accordance with the prescribedtherapy. This is especially true when different sets of tablets must betaken at different times of day. To provide a memory aid which helps thepatient take his or her medicaments correctly and also to ensure areliable overview as to which medicaments have already been taken, DE 102004 034 024 A1 describes a blister pack in which the drug pockets arearranged in a matrix divided into days of the week and administrationtimes with seven lines and at least three columns. The individual drugpockets are designed as tub-like wells formed in a thin layer ofplastic, and all the tablets which are to be taken at a particular timeof day are put together in one of these wells. All the drug pockets arecovered with blister film, and the sections assigned to the individualadministration times are separated from each other by perforations, sothat the individual administration sections for certain times of day andcertain days of the week can be easily separated from the rest of thepack.

A method for producing a packaging unit of this type to accommodate thepatient's medicaments for a week is known from, for example, DE 10 2004020 510 A1. Strip-like supply-blister packs containing the individualmedicaments are wound up into rolls. At various dispensing stations, thestrips are conveyed over the above-described packaging unit in thetransverse direction, and plungers are used to push the medicaments outof the strip-like supply-blister pack into the tub-like wells of thepackaging unit. The packaging unit, designed as a “one-week blister”, issealed as a whole with sealing film.

The above-mentioned production method is relatively cumbersome, however,because of the complicated mechanisms required and the double packagingstep of the tablets. The method is also critical from a contaminationstandpoint, because, when the tablets are pushed out by the plungers,tablet dust is created, which settles on the plungers and in thetub-like wells.

Another production method is known from DE 10 2005 047 429 A1. Here asystem for filling one-week blister packs is disclosed, which isintended primarily for situations in which comparatively small numbersof patients are involved (e.g., in clinical centers). Standardcommercial blister packs are stored in stacks in sector magazines, eachof which can be rotated to release a blister holding the desired type oftablet. The blister pocket, from which the tablet is to be taken, isthen opened by punching out the blister cap. The blister cap is thenremoved by a suction pipette integrated into the punching tool,whereupon the suction pipette is also used to remove the tablet from theblister pocket and to load it into the one-week blister pack. Theoverall method is extremely complicated.

SUMMARY OF THE INVENTION

It is an object of the present invention to create a method forproducing a multi-day package holding various drugs, the methodexcluding contamination and being carried out easily and also veryquickly.

According to an embodiment of the invention, the method for producing amulti-day package with various drugs includes the following steps: abottom layer is formed with a plurality of wells arranged in a pattern;a predetermined number of different drugs is arranged in predeterminedpositions at various dispensing stations of a filling device; thedesired number of drugs are picked from their predetermined positions byat least one movable suction or gripper device; the medicaments aredeposited in the predetermined wells; and a sealing film is applied tothe bottom layer to seal off the wells. In the course of this method,several suction or gripper devices, which are arranged in correspondencewith the pattern of the wells in the multi-day package and which aremovable parallel to each other, are actuated individually in at leastone dispensing station.

Thus, a multi-day package containing various drugs is produced in anespecially simple manner, quickly and without risk of contamination.

In one embodiment, the arrangement of a predetermined number of a drugin predetermined positions at a dispensing station of a filling deviceincludes the following steps: a base layer extending a considerabledistance in the longitudinal and transverse directions is formed, as aresult of which a plurality of supply-blister pockets is obtained; drugsare loaded into the supply-blister pockets; the supply-blister pocketsare sealed by a temporary sealing film, which is applied adhesively tothe webs of the base layer between the supply-blister pockets, as aresult of which a supply-blister sheet is formed; and the temporarysealing film is partially removed from the supply-blister sheet torelease a predetermined number of drugs to the suction or gripperdevices. As a result, it is guaranteed that the drugs remain protectedin the supply-blister pockets even during long periods of storage.

It can be advantageous to cut the supply-blister sheet intosupply-blister sections before the step of removing the temporarysealing film and to arrange the wound-up blister sections at thedispensing stations transversely to the transport direction of themulti-day package. As a result, effective access to individual,seldom-used tablets is possible. The supply-blister sections are notnecessarily limited to a single strip-like row of supply-blister pocketsbut can have instead several supply-blister pockets next to each other,so that the simultaneous removal of drugs from several supply-blisterpockets by several suction or gripper devices is possible not onlytransversely, but also longitudinally to the transport direction of themulti-day package.

In another embodiment, the arrangement of a predetermined number of adrug in predetermined positions at a dispensing station of a fillingdevice can also include the step of filling the holders of a sortingplate with drugs, the holders being arranged in accordance with thepattern of the wells of the multi-day package. This is especiallyeffective when a large number of these drugs are to be packed into eachmulti-day package. The sorting plate can be very easily filled by usinga vibrating chute to supply the tablets and then to apply brushingmovement.

It is also possible to apply the two embodiments of the method describedabove in combination, that is, at different dispensing stations of thesame device.

To simplify quality control, the suction or gripper device is preferablymonitored by a camera or by means of sensors.

By means of the additional step of introducing perforations into thebottom layer and into the sealing film between the wells, thepossibility is obtained of being able to separate individual sectionsfor specific administration times of specific days from the multi-daypackage.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional details, features, and advantages of the present inventioncan be derived from the following description, which makes reference tothe attached drawings.

FIG. 1 is a schematic top view of a multi-day package containing variousmedicaments after the sealing film has been partially removed;

FIG. 2 is a cross-sectional view through the multi-day package of FIG.1;

FIG. 3 is a flow chart of a first alternative of the inventive methodfor producing the multi-day package;

FIG. 4 is a flow chart of a second alternative of the inventive methodfor producing the multi-day package;

FIG. 5 is a schematic diagram of a first filling method which can beused in the inventive production method; and

FIG. 6 is a schematic diagram of a second filling method which can beused in the inventive production method.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a schematic top view of an example of a multi-day package 1.The packaging unit 1 comprises several segments 3, each of which isassigned to a certain time of day of a certain day of the week and canhold several medicaments. The segments 3 are arranged in columns androws and are preferably separated by perforations 2, wherein, in theexemplary embodiment shown here, the first row 4 stands, for example,for “Monday”, the second row 5 for “Tuesday”, etc. The division intocolumns corresponds to the different administration times of themedicaments during the course of a specific day of the week, wherein,for example, the first column 6 is assigned to the administration time“morning”, the second column 7 to the administration time “noon”, thethird column 8 to the administration time “evening”, and the fourthcolumn 9 to the administration time “night”. It is also possible topackage medicaments for more than 7 or less than 7 days in the multi-daypackage (e.g., a blister pack for a whole month) or to include onlycertain administration times.

FIG. 2 is a cross-sectional view of part of an inventive packaging unit1 with several adjacent segments 3. The segments 3 are formed out of abottom layer 11, into which relatively large wells 10 are formed, eachof which can hold several drugs. The bottom layer 11 consists preferablyof PVC film, either transparent or of any desired color, or it canconsist of polypropylene or a layer laminate with aluminum. The wells 10can also have a shape different from the tub-like form shown in FIG. 2and can also be arranged in almost any regular or irregular pattern,possibly a circular pattern, for example.

Each well 10 is closed by a sealing film 12, which is bonded adhesivelyto the webs 14 of the bottom layer located between the wells 10.Aluminum foil, paper-lined foil, or polypropylene film can be used asthe sealing film 12. The sealing film 12 has no perforations in theareas where it covers the wells 10, so that a secure and long-lastingseal is provided for the drug until it is needed. The perforations 2 inthe webs 14 of the bottom layer 11, which form the boundaries of thewells 10, and those in the sealing film 12 can be seen between theindividual segments 3.

When the sealing film 12 is pulled from the webs 14 around a well 10, itis therefore possible to access all of the medicaments intended for acertain administration time at once. For this purpose it is importantfor the sealing film 12 to be relatively tear-proof.

The sealing film 12 can also be imprinted with a list of the medicamentscontained in the individual wells 10. It is also conceivable that anadditional hinged cover could be provided, on which information aboutthe medicaments is presented.

A flow chart of a first embodiment of the inventive method for producingthe multi-day package is shown in FIG. 3.

First, wells 10 to hold the drugs are formed in a bottom layer 11 (step32). For this purpose, the bottom layer 11 is pulled from a roll,possibly heated in a heating station, and then provided with the wells10 in a following forming station.

Then a predetermined number of different drugs are arranged (step 34) inpredetermined positions at various dispensing stations of the fillingstation. The steps to be carried out for this purpose in the case of theembodiment according to FIG. 3 are explained in the following.

First, in step 35, a base layer of considerable size in the longitudinaland transverse directions is formed, as a result of which a large numberof supply-blister pockets 16 is obtained. For this purpose, the baselayer is unwound from a roll, possibly heated in a heating station, andprovided with the supply-blister pockets 16 in a forming station. Thenthe supply-blister pockets 16 are filled with drugs (step 36); theresults are subjected to quality control, and defective products areejected. In the following step 38, the supply-blister pockets 16 areclosed by a temporary sealing film, which is applied adhesively to thewebs of the base layer between the supply-blister pockets 16. For thispurpose, the temporary sealing film is unwound from a roll, applied in asealing station to the webs of the base layer between the supply-blisterpockets 16, and then cooled in a cooling station.

Then the large supply-blister sheet thus produced is cut into individualsupply-blister sections (step 40). The cutting of the supply-blistersheet into separate supply-blister sections comprises preferably thecutting of the supply-blister sheet in the longitudinal direction bymeans of a longitudinal cutter. In the longitudinal cutter, thesupply-blister sheet is cut in the direction in which the supply-blistersheet is traveling. The cuts are made preferably by circular knivesmounted on a shaft. This shaft will usually be located underneath thesupply-blister sheet. Above the supply-blister sheet there is a shaft onwhich a round disk is mounted opposite each of the circular knives. Thecut edge is formed between the circular knife and the round disk.Hold-downs press the supply-blister sheet from above against the guideto ensure a straight cut. The longitudinal cutter is usually driven by amotor and a toothed belt.

As a result, supply-blister sections are produced from thesupply-blister sheet, and these sections are then wound up into rolls. Asupply-blister section can be in the form of a strip, but it can alsohave several supply-blister pockets 16 adjacent to each other in thetransverse direction. After that, the supply-blister sections areunwound from the roll, and the temporary sealing film is removed (step42).

Then the medicaments are picked up in a controlled manner by means ofthe movable suction or gripper devices 50 and placed in the wells 10(step 44).

FIG. 5, which is a schematic diagram of a filling method for theabove-mentioned embodiment, illustrates an example of a suction device50, which can move in the transverse direction. In this schematicdiagram of an exemplary embodiment, the suction device 50 is a suctionarm, which can move vertically and which is driven by a control unit(not shown). The device is designed to pick up individual tablets fromthe supply-blister pockets 16 from which the sealing film 12 haspreviously been removed and to place them in the individual desiredwells 10 formed in the bottom layer 11. Movement in the transversedirection along a rail 52 is also conceivable, but any other guidedmovement which can be controlled by the control unit can be used here.

Even though only one suction arm 50 is shown in the schematic diagram,several parallel suction arms 50 are used according to the invention,which are actuated independently so that several tablets can beintroduced into the wells 10 simultaneously. The bottom layer 11 ispreferably transported in interval fashion, and the multi-day package 1will be filled with the individual tablets row by row. Thus, severalrows or segments 3 can be filled simultaneously. For this purpose it canalso be advisable for the suction arms 50 to be movable in the transportdirection of the multi-day package as well.

A camera 54, which is installed in the area of the suction devices andwhich preferably moves along with them, serves to monitor both thesuction method and the correct placement of the tablets in the wells 10of the bottom layer 11. Other sensors are also suitable for monitoringthe picking and placing of the tablets.

The last step is the sealing of the multi-day package with the sealingfilm 12 (step 46).

The arrangement 34 of a predetermined number of a drug in predeterminedpositions at a dispensing station of the filling device can also becarried out in accordance with a second embodiment, as can be seen fromFIGS. 4 and 6.

In this case, the holders of a sorting plate 56, which are arranged incorrespondence with the pattern of the wells 10 in the multi-daypackage, are filled with drugs. The individually controlled suction orgripper devices 50 can be arranged above the sorting plate 56 incorrespondence with the pattern of the holders. This is especiallyeffective when large numbers of these drugs are to be packed into eachmulti-day package. The placing of the drugs onto the sorting plate 56 ispreferably accomplished by means of a vibrating chute. To ensure thatall of the holders of the sorting plate 56 are filled, a brushingmovement with a brush device 58 is then preferably carried out, whichalso takes care of removing excess tablets from the sorting plate 56.

By means of the filling method shown schematically in FIG. 6, where, forreasons of clarity the sorting plate 56 is shown reduced in size andwhere only two suction devices 50 of the matrix arrangement of suctiondevices 50 corresponding to the pattern of wells 10 in the multi-daypackage are shown, it is possible to pick the drugs from the sortingplate 56 in any desired pattern and to place them in the correspondingwells 10 in the multi-day package, whereupon the empty holders arerefilled.

It is possible to apply the embodiments of the method described above incombination, that is, at different dispensing stations of the samefilling device.

Thus, in an especially simple and rapid manner, a multi-day package forvarious drugs is created, in which the medicaments are sorted byadministration times.

1. A method for producing a multi-day package containing various drugscomprising the following steps: forming a bottom layer with a pluralityof wells arranged in a pattern; arranging a predetermined number ofdifferent drugs in predetermined positions at various dispensingstations of a filling device; picking the desired number of drugs in acontrolled manner from their predetermined positions at each dispensingstation by at least one movable suction or gripper device, and placingthe drugs in predetermined wells; and applying a sealing film to thebottom layer to seal off the wells, wherein, in at least one dispensingstation, several suction or gripper devices are arranged incorrespondence with the pattern of the wells in the multi-day package,are actuated individually and travel parallel to each other.
 2. Themethod of claim 1 wherein the step of arranging a predetermined numberof a drug in predetermined positions at a dispensing station of afilling device includes the following steps: forming a base layerextending a considerable distance in the longitudinal and transversedirections, as a result of which the plurality of supply-blister pocketsis obtained; and loading the drugs into the supply-blister pockets;sealing the supply-blister pockets with a temporary sealing film, whichis applied adhesively to the webs of the base layer between thesupply-blister pockets, as a result of which a supply-blister sheet isformed; and partially removing the temporary sealing film from thesupply-blister sheet to release a predetermined number of drugs to thesuction or gripper devices.
 3. The method of claim 2 further comprisingthe additional step that, before the step of removing the temporarysealing film from the supply-blister sheet, the supply-blister sheet iscut into supply-blister sections, and the supply-blister sections arearranged on rolls at the dispensing station transversely to thetransport direction of the multi-day package.
 4. The method of claim 1wherein the step of arranging a predetermined number of a drug inpredetermined positions at a dispensing station of a filling devicecomprises the step of filling the holders of a sorting plate with drugs,the holders being arranged in correspondence with the pattern of themulti-day package.
 5. The method of claim 4 wherein the sorting plate isfilled completely by an oscillating movement of a vibrating chute,followed by a brushing movement of a brush device.
 6. The method ofclaim 1 wherein each of the minimum of one suction or gripper devices ismonitored by means of a camera or by sensors.
 7. The method of claim 1further comprising the additional steps that perforations are introducedinto the bottom layer and into the sealing film between the wells.